Diagnoza Manual

ASE 7 - Heating, Ventilation &
Air Conditioning
Module 5
Automatic HVAC Systems
Acknowledgements
General Motors, the IAGMASEP Association Board of Directors, and Raytheon Professional
Services, GM's training partner for GM's Service Technical College wish to thank all of the
people who contributed to the GM ASEP/BSEP curriculum development project 2002-3. This
project would not have been possible without the tireless efforts of many people. We
acknowledge:
The IAGMASEP Association members for agreeing to tackle this large project to create
the curriculum for the GM ASEP/BSEP schools.
The IAGMASEP Curriculum team for leading the members to a single vision and
implementation.
Direct contributors within Raytheon Professional Services for their support of translating
a good idea into reality. Specifically, we thank:
Chris Mason and Vince Williams, for their leadership, guidance, and support.
Media and Graphics department under Mary McClain and in particular, Cheryl
Squicciarini, Diana Pajewski, Lesley McCowey, Jeremy Pawelek, & Nancy
DeSantis.
For his help on the Heating, Ventilation, and Air Conditioning curriculum volume,
Subject Matter Expert, Brad Fuhrman, for his wealth of knowledge.
Finally, we wish to recognize the individual instructors and staffs of the GM ASEP/BSEP
Colleges for their contribution for reformatting existing General Motors training material, adding
critical technical content and the sharing of their expertise in the GM product. Separate
committees worked on each of the eight curriculum areas. For the work on this volume, we
thank the members of the Heating, Ventilation, and Air Conditioning committee:
Steve Ash, Sinclair Community College
Warren Farnell, Northhampton Community College
Rick Frazier, Owens Community College
Marvin Johnson, Brookhaven College
Chris Peace, J. Sargeant Reynolds Community College
Vince Williams, Raytheon
Contents
Module 5 Automatic HVAC Systems
Acknowledgements .............................................................................................. 2
Introduction .......................................................................................................... 4
Objectives ............................................................................................................ 4
Lesson 1: Automatic HVAC Overview ................................................................................. 6
Air Distribution System .......................................................................................................... 8
Lesson 2: Modes of Operation ........................................................................................... 11
Re-Calibrating Actuators or HVAC Controller. ..................................................................... 25
Lesson 3: Special Operating Modes and Blower Controls ................................................. 26
Blower Control .................................................................................................................... 29
Lesson 4: Sensors .............................................................................................................31
Lesson 5: Automatic Dual Zone System ............................................................................ 36
Lesson 6: Automatic Rear HVAC System .......................................................................... 38
Lesson 7: Steering Wheel Controls ................................................................................... 41
Lesson 8: Automatic HVAC System Diagnosis .................................................................. 44
Module #5 Post-test ............................................................................................................ 52
Exercise Lesson 1 & 2 ....................................................................................................... 58
Automatic HVAC Systems Overview................................................................................... 58
Exercise Lesson 2
Automatic HVAC - Program Number (On Vehicle) .............................................................. 59
Exercise Lesson 3............................................................................................................... 62
Special Operating Modes and Blower Control .................................................................... 62
Exercise Lesson 4
Automatic HVAC Service Information ................................................................................. 63
Exercise Lesson 8............................................................................................................... 65
Automatic HVAC Controls Diagnosis .................................................................................. 65
Introduction
Student Workbook
This module is about a type of HVAC control that came into being some
time after manually controlled HVAC systems were introduced. An
overview of the unique features of the automatic HVAC control systems,
detailed information on unique control system components, and some tips
on diagnosing customer concerns will be discussed. In automatic HVAC
operation, the HVAC control module will maintain the comfort level inside
of the vehicle by controlling the A/C compressor clutch, the blower motor,
the air temperature actuators, mode actuator and recirculation. This
module will discuss these controlled operations.
ASE 7 - HVAC
Module 5 Automatic HVAC
Systems
This module will further explore:

1. The automatic dual zone system
2. Automatic rear (auxiliary) HVAC systems
3. Steering Wheel controls
4. Automatic Blower operation
5. Types of sensors and operation
6. Unique operational features designed into automatic HVAC systems
Objectives
1. Be able to identify and explain the basic functions, controls and
designs of an automatic HVAC system.
2. Be able to identify and understand the operation of sensor
components.
3. Be able to explain the function and operation of an automatic dual
zone air distribution system.
4. Obtain knowledge of the components and operations of an automatic
rear air distribution system.
5. Be able to explain automatic blower operation.
6. Understand the function and operation of steering wheel controls.
7. Given the parameters of a particular automatic HVAC customer
concern, a student will be able to apply strategy based diagnostic
procedures to resolve the problem.
2002 General Motors Corporation

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5-4
NATEF Area VII.
Student Workbook
1. Diagnose temperature control problems in the heater/ventilation

system; determine necessary action.
ASE 7 - HVAC
2. Diagnose malfunctions in the electrical controls of heating, ventilation,

and A/C. (HVAC) systems; determine necessary action.
3. Inspect and test A/C heater control panel assembly; determine
necessary action.

Systems
4. Check operation of automatic and semi-automatic heating, ventilation,

and air conditioning (HVAC) control systems; determine necessary
action.
STC Tasks:
1. Describe the air distribution system used in HVAC systems.
2. Understand automatic HVAC system components, function and
design.
3. Locate automatic HVAC system components.
4. Understand unique automatic HVAC component operation.
5. Understand the cause of automatic HVAC system malfunctions.
6. Understand the components, function, design and operation of
automatic dual-zone HVAC systems.
7. Understand the components and operation used in automatic rear
HVAC systems.
8. Understand the operation of automatic dual-zone, rear HVAC systems.
9. Understand steering wheel components, operation, function and
design.
10. Apply the GM SBD process to automatic and dual-zone HVAC
concerns.

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5-5
Lesson 1: Automatic HVAC Overview
Student Workbook
The automatic HVAC system (or automatic climate control system) is

designed to provide a comfortable environment inside the passenger
compartment, regardless of weather conditions outside of the vehicle. This
is achieved by cooling, dehumidifying, heating and circulating the air that
enters the passenger compartment. The automatic HVAC systems are
equipped with a controller containing a microprocessor that uses inputs
and outputs to control the operation of the HVAC system. The
microprocessor can be located in either the control head, Body Control
Module (BCM) or Instrument Panel Module (IPM). The automatic HVAC
system allows the vehicle operator to choose either automatic control or
manual control (refer to Figure 5-1). When automatic control is selected,
the only input required from the operator is the desired interior
temperature (the SET temperature). When the desired temperature is
input, the controller automatically selects the appropriate air intake,
discharge outlet(s), fan speed and discharge air temperature to maintain
the SET temperature. The system can automatically regulate and maintain
the inside air temperature from 65F (18C) to 85F (29C) regardless of
changes in ambient air temperature. The desired temperature can also be
set to 60F (16C) and 90F (32C). At these SET temperatures, the
system provides unregulated max cooling or max heating. The controller
will not try to maintain these temperatures.
ASE 7 - HVAC
Systems
AUTOMATIC CONTROL
Operator Inputs
SET Temperature
HVAC Controller
Sensor Inputs
Temperature Sensors
Sun Load Sensors
A/C Sensors
Vehicle and Engine
Speeds
Automatic
Control Logic
Automatically Controlled
Outputs
Inlet Mode Door

Temperature Door(s)
Outlet Mode Doors
Blower
A/C Compressor
FULL MANUAL CONTROL

Manually Controlled
Outputs
Operator Inputs
HVAC Controller
Fan Speed
Mode Selection
SET Temperature
Inlet Mode Door

Outlet Mode Doors
Blower
Manual Control
Sensor Inputs
Temperature Sensors
Sun Load Sensors
A/C Sensors
Vehicle and Engine
Speeds
Automatically Controlled
Outputs
Automatic
Control Logic
Temperature Door(s)
A/C Compressor
Figure 5-1, Full Automatic Mode versus Full Manual Mode

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5-6
Manual control allows the operator to take control over the mode door
positions and/or the blower speed. The controller will continue to maintain
the SET temperature (if possible) even when manual selections are made.
Some manual selections make it difficult or impossible for the controller to
maintain the SET temperature. Like manual HVAC systems, the automatic
HVAC systems have the following sub-systems (refer to Figure 5-2):
Refrigeration System (one of two types):
Student Workbook
ASE 7 - HVAC
Systems
Cycling Clutch Orifice Tube (CCOT) System

Variable Displacement Orifice Tube (VDOT) System
Cooling System (includes the following):

Heater Core
Radiator
Air Intake System
Air Distribution System
Figure 5-2, Automatic HVAC Sub-Systems

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5-7
Air Distribution System

The air distribution system contains air door/valves that control the air
inlets and outlets (mode doors) and a door/valve (temp, blend or mix door)
that controls the temperature. On dual zone air distribution systems there
are two temperature doors (refer to Figure 5-3). The air distribution system
also contains a blower motor and fan that is used to circulate the air. The
position of the mode doors, temperature door(s) and blower motor speed
is determined by the selections made by the vehicle operator. In the
automatic mode of operation, the controller determines the appropriate
operation of the HVAC system to maintain the SET temperature. In the
manual modes of operation, the selections made at the control head
directly affect door positions and blower speed.
Student Workbook
ASE 7 - HVAC
Systems
There are two control methods used to control the air doors in an
automatic HVAC system:
Vacuum
Electronic
Some automatic HVAC air distribution systems use different control

methods to control different doors. Therefore, it is common to see a
system with mode doors controlled by vacuum solenoids and a
temperature door controlled electronically. When the doors are controlled
by vacuum solenoids, the solenoids can be located in either the HVAC
programmer or inside a solenoid box. All automatic HVAC systems use
electric motors to control the temperature door(s).
Figure 5-3, Automatic HVAC Air Distribution Systems (Single and Dual Zone)

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5-8
Figure 5-4 shows an auto HVAC air distribution system that uses electric
motors to control both the mode doors and the temperature doors. All of
these motors are the new style two-wire motors. These actuators are twowire bi-directional electric motors. Two control circuits enable the actuator
to operate. The control circuits use either a 0 or 12-volt value to
coordinate the movement. When the actuator is at rest, both control
circuits have a value of 12 volts. In order to move the actuator, the HVAC
control module grounds the appropriate control circuit for the commanded
direction. The HVAC control module reverses the polarity of the control
circuits to move the actuator in the opposite direction.
Student Workbook
ASE 7 - HVAC
Systems
The HVAC control module determines the door position by counting motor
pulses on one of the control circuits. These pulses are small voltage
fluctuations that occur when the brush is shorted across two commutator
contacts as the motor rotates. As the actuator shaft rotates, the HVAC
control module monitors the voltage drop across an internal resistance to
detect the pulses. The HVAC control module uses a range of 0-255
counts to index the actuator position.
The system in Figure 5-4 is a dual zone system with an auxiliary rear
HVAC system. This system has an additional motor to allow the
passenger to control the passenger side temperature door and an
auxiliary motor to control the rear temperature.
Figure 5-4, Automatic HVAC System using two-wire motors (Cadillac)

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5-9
Figure 5-5 shows an automatic Dual Zone HVAC air distribution system
that uses vacuum solenoids located inside a solenoid box. The HVAC
control head controls the groundside of the solenoids. When a solenoid is
grounded, vacuum is applied to the vacuum actuator for a specific door(s).
When the ground path is removed, the vacuum actuator is allowed to vent.
The temperature door is operated by a new style five-wire motor. The logic
circuits inside the motor, control the bi-directional electric motor based on
the input voltage provided by the control head on the signal wire. When
0 volts is applied to the signal circuit, the motor logic circuits rotate the
motor in one direction. When 5 volts is applied to the signal circuit, the
motor logic circuit rotates the motor in the other direction. If 2.5 volts is
applied to the signal circuit, the motor will stop rotating.
Student Workbook
ASE 7 - HVAC
Systems
Inside the motor is a potentiometer that is mechanically linked to the air

door. The control head uses the potentiometer for feedback on the actual
position of the door.
Using this feedback, the controller will operate the motor until the desired
position is achieved.
Figure 5-5, Automatic HVAC System using Vacuum Solenoids (Buick)

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5-10
Lesson 2: Modes of Operation
Student Workbook
The automatic HVAC systems use a controller, Body Control Module

(BCM) or an Instrument Panel Module (IPM) to control the various
functions of the HVAC system. The amount of control it has over the
system is based on the selections made by the vehicle operator. If the
vehicle operator selects the AUTO mode of operation, the controller will
have control of the mode doors and/or blower. Although manual control
prevents the controller from automatically operating certain HVAC
functions, it will try to reach or maintain the SET temperature.
ASE 7 - HVAC
Systems
The SET temperature is the desired temperature that is selected by the

vehicle operator. It allows the operator to select a specific temperature at
which the controller will maintain the passenger compartment. In order for
the controller to reach and maintain the SET temperature, it must have
information on the heat load, engine coolant temperature and the
difference between the actual interior temperature and the SET
temperature. Although heat load is not a major factor when heating is
required, it is critical when the interior needs to be cooled. The controller
uses the following inputs to determine this information:
Interior Temperature
SET Temperature
Exterior (Ambient) Temperature
Engine Coolant Temperature
Sun Load
Vehicle Speed
Outlet (Duct) Temperature
Based on these inputs, the controller generates a program number. The

controller uses this number to determine how the temperature door(s),
mode doors, and blower should be controlled to reach and maintain the
SET temperature (refer to Figure 5-6). This number can be from 0 to 255
(0% to 100%) and indicates the amount of heating or cooling required.
The controller commands maximum cooling when the program number is
0 and maximum heating when the number is 255. This number will
fluctuate as the heating and cooling requirements change.
Figure 5-6, The Effect of Program Number on the HVAC System in AUTO Mode

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5-11
If the vehicle operator takes manual control of the mode doors and/or
blower, it can impact the heating and cooling requirements. This will
impact the program number. The amount of change in the program
number during manual control is based on the manual selections and how
they impact the cooling and heating requirements. If the operator takes
control of the blower using the fan control switch, it can affect the heat
exchange rates at both the evaporator and the heater core. This can
affect the passenger compartment temperature. To compensate for this,
the controller may have to change the temperature door position and
possibly the position of the mode doors if they are still under automatic
control (refer to Figure 5-7). This change in strategy will be reflected in the
program number.
Student Workbook
ASE 7 - HVAC
Systems
Figure 5-7, HVAC system Operation when Manual Blower Control is Selected
During manual control of the mode doors, the controller loses automatic
control over the mode doors. Manual mode selections force the controller
to move the inlet and outlet doors to the correct positions for the selected
mode and maintain these positions until the operator changes the mode.
Manual mode selections do not affect the automatic control of the
temperature. However, the controller may need to adjust the control
strategy for the temperature door and the blower (if it still has control of
the blower) to maintain the SET temperature (refer to Figure 5-8). Some
manual modes greatly restrict the controller in its ability to reach and
maintain the SET temperature by preventing operation of the A/C
compressor and the blower.
Manually selecting mode door positions does not necessarily affect the
controller's ability to automatically control the blower speed. The controller
will continue to automatically operate the blower to maintain the SET
temperature unless the manual mode prevents blower operation or the
operator has taken manual control of the blower.

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5-12
Student Workbook
ASE 7 - HVAC
Systems
Figure 5-8, HVAC System Operation when Manual Mode Control is Selected
Figure 5-9 shows the effects of the vehicle operator taking manual control
of both the blower and the mode doors (full manual control). The only
automatic control that the HVAC controller has is over the positions of the
temperature door and the A/C compressor. However, some modes will
prevent compressor operation. In full manual mode, the controller will still
try to reach and maintain the SET temperature, but its ability to do this can
be greatly affected by the manual selections.
Figure 5-9, HVAC System Operation in Full Manual Mode

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5-13
The following pages explain the operation of the automatic HVAC system
in the various modes of operation. Many of the modes of operation can
be selected manually or are selected by the controller in AUTO mode as
part of the strategy to reach and maintain the SET temperature. Those
modes of operation that are strictly manual modes can only be accessed
by manual selections on the control head (Figure 5-10). The controller
cannot automatically select these modes.
Student Workbook
ASE 7 - HVAC
Systems
The following is an example of the manual selections and the selections

that can be automatically made by the controller (2003 Park Avenue)
OFF (manual mode selection)
AUTO (manual mode selection)
VENT (manual mode selection)
DEFOG or FLOOR/WINDSHIELD (manual mode selection)
BI-LEVEL or MID/FLOOR (automatic and manual mode selection)
A/C or MID (automatic and manual mode selection)
HEATER or FLOOR (automatic and manual mode selection)
FRONT DEFROSTER (automatic and manual mode selection
RECIRC or MAX A/C (automatic and manual mode selection)
Figure 5-10, Manual and Automatic Selection Using the Control Head

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5-14
OFF Mode
Student Workbook
When OFF is selected on an automatic HVAC system, the blower motor

and the A/C compressor will not operate. However, in this mode the
controller still remains active and tries to reach the desired SET
temperature. On some dual zone systems, the OFF button must be
pressed twice to turn the system off. The first press of the button will
disable passenger control of the passenger side temperature door.
ASE 7 - HVAC
Systems
If the SET temperature is 70F (21C) when the system is in the OFF
mode and it is a cold day, the system will try to achieve the SET
temperature by allowing air to flow through the heater core (Figure 5-11).
Since the blower does not operate in this mode, airflow is only generated
when the vehicle is moving. The air flowing over the exterior
The vehicle increases the air pressure just ahead of the windshield and
forces some air into the air distribution system, creating a small airflow.
The air exits the system through the heater (floor) and defrost (windshield)
outlets.
When the outside temperature is higher than the SET temperature, the
system can only lower the inside temperature to the same temperature as
the outside (ambient) air. This is because the compressor will not operate
in the OFF mode.
The period of time that it takes to reach the SET temperature in the OFF
mode may take longer than if another mode was selected that allows
blower operation. The OFF position does not affect the rear defog,
ambient temperature or SET temperature.
Figure 5-11, Automatic HVAC Air Distribution OFF Mode

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5-15
AUTO Mode
Student Workbook
In AUTO mode, all HVAC functions are controlled automatically by the

controller, based on various inputs (including the SET temperature).
During automatic control, the controller will select the correct blower speed
and door positions to reach and maintain the SET temperature. In the
AUTO mode, the controller can control the inlet, outlet and temperature
doors. It can also control blower speed and the operation of the A/C
compressor.
ASE 7 - HVAC
Systems
The position of the inlet air door is based on interior, exterior and SET
temperatures (Figure 5-12). In most situations, the inlet door will be
positioned to allow outside air to flow into the air distribution system.
However, during A/C compressor operation, the inlet door may be
positioned in the recirculation position. This will allow the air in the
passenger compartment to be recirculated. This usually occurs when the
passenger compartment air temperature has dropped below the
temperature of the outside air. The inlet door is not typically positioned in
the recirculation position when the interior air temperature is higher than
the outside air temperature since the interior air has a higher heat load.
Figure 5-12, Inputs and Outputs used in AUTO Modes

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5-16
The position of the temperature door is also based on the interior, exterior
and SET temperatures. The controller will determine the heating and
cooling requirements by comparing the SET temperature to the interior
temperature. The controller will also compensate for the exterior air
temperature if the air is being pulled from the outside.
The temperature door controls the amount of air that flows through or
bypasses the heater core. If the interior temperature must be lowered, the
controller will restrict the airflow through the heater core and may enable
the compressor. If the interior temperature must be increased, the
controller will position the temperature door to allow more air through the
heater core. This strategy is used regardless of the operation of the A/C
compressor.
Student Workbook
ASE 7 - HVAC
Systems
The exit path that the conditioned air (heated or cooled) takes is based on
the heating and cooling requirements.
In general, the controller will provide one of the following three exit paths:
Floor/heater and
rear outlets
A/C and rear

outlets
Heater, A/C and

rear outlets
The operation of the

blower and the A/C
compressor are also
directly related to the
heating and cooling
Figure 5-13, Air Distribution System
requirements. The
blower speed is increased when more airflow is required to achieve the
SET temperature and decreased when maintaining the SET temperature.
On some systems, the blower speed can be adjusted by the vehicle
operator in AUTO mode by pressing the fan control switch once. This
results in a slight increase or decrease (AUTO HI or AUTO LO) over the
speed selected by the controller. Pressing the fan control switch twice in
the same direction, causes the fan to operate at a fixed speed. On other
systems, adjusting the fan control switch overrides automatic blower
control and allows the operator to manually select the blower speed.
Compressor operation can occur at both high and low ambient
temperatures. When the ambient temperature is high, the refrigeration
system is used to lower the temperature of the air entering the passenger
compartment. When the ambient temperature is low, approximately 40F
(4C), the refrigeration system is used to dehumidify the air before it exits
the air distribution system. This is used to decrease the amount of
condensation on the windows.

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5-17
DEFOG or FLOOR/WINDSHIELD Mode

The defog mode is a manual selection used to remove humidity from the
interior of the vehicle. When the ambient air temperature is low, the
humidity inside the passenger compartment can condense on the
windows and obstruct vision. To remove the humidity, the controller
positions the inlet air door to the outside air position and uses the
refrigeration system to dehumidify the air (Figure 5-14).
Student Workbook
ASE 7 - HVAC
Systems
The controller will only enable the A/C compressor when the temperature
is above approximately 40F (4C) and will continue to operate the
compressor to maintain an evaporator temperature of approximately 33F
(1C). The dehumidified air is forced out of both the heater (floor) outlets
and defrost (windshield) outlets.
Although the DEFOG mode allows the vehicle operator to manually select
the position of the outlet air doors(s), the controller will continue to
automatically maintain the temperature (using the temperature door) and
blower speed. The fan control switch can be used to override or slightly
adjust (system dependent) the automatic control of the blower. On
systems that utilize an AIR FLOW button (Buick) or a MODE button
(Pontiac), this mode of operation will be indicated by FLOOR/
WINDSHIELD on the display.
Figure 5-14, Air Distribution System in DEFOG Mode

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5-18
DEFROST Mode
Student Workbook
The DEFROST mode (manually or automatically selected) is used to

remove condensation and frost on the front windshield. It also helps
prevent additional frost and condensation from forming. In this mode, the
controller positions the inlet air door to the outside air position and uses
the refrigeration system to dehumidify the air (Figure 5-15).
The controller will only enable the A/C compressor when the temperature
is above approximately 40F (4C) and will continue to operate the
compressor to maintain an evaporator temperature of approximately 33F
(1C). Unlike the DEFOG mode, the majority of the dehumidified air is
forced out of the defrost outlets with a slight bleed to the floor outlets.
ASE 7 - HVAC
Systems
Although manual selection of the DEFROST mode allows the vehicle

operator to manually select the position of the outlet air door(s), the
controller will continue to automatically maintain the temperature (using
the temperature door) and blower speed. The fan control switch can be
used to override or slightly adjust (system dependent) the automatic
control of the blower.
On some systems (Cadillac E/K), the DEFROST mode is not stored in the
controller memory after the ignition is turned to the OFF position. In this
case, the system will switch to the AUTO mode in the next key cycle.
Figure 5-15, Air Distribution System in DEFROST Mode

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5-19
RECIRC Mode
Student Workbook
The RECIRC or MAX A/C (on some systems) mode is used to position the
inlet air door to the recirculation position, allowing a 90% recirculation of
the passenger compartment air (Figure 5-16). This mode is automatically
selected when the SET temperature is 60F (16C). Some systems have a
separate RECIRC button, which allows recirculating passenger
compartment air in other modes. On all systems, a slight amount of
outside air is allowed to bleed into the air distribution system for
ventilation.
ASE 7 - HVAC
Systems
The air outlets used in the RECIRC mode are based on whether the
system is in AUTO mode or in one of the other modes. When 60F (16C)
is selected in AUTO mode, the refrigeration system is operating and the
air exits through the A/C (panel) outlets with a slight bleed to the floor
outlets. If the RECIRC mode is selected in one of the other modes, the
position of the outlet door(s) will be based on that mode. RECIRC is not
available for use in the DEFROST mode since it could cause windshield
fogging.
In the RECIRC mode, the controller will continue to automatically maintain
the temperature (using the temperature door) and blower speed. The fan
control switch can be used to override or slightly adjust (system
dependent) the automatic control of the blower.
On many systems, the RECIRC mode will continue to operate throughout
the entire ignition cycle, unless manually stopped by pressing the RECIRC
button with the system in the OFF position. This will return the system to
the last setting prior to being turned OFF. On other systems (2003 H and
C cars), the RECIRC mode will operate for about 10 minutes before it
automatically turns off and the inlet door moves to the outside air position.
On these systems, any mode changes or ignition cycles will cancel the
RECIRC mode and position the inlet air door to the outside air position.
The recirculation actuator will also move automatically when coolant
temperatures reach 117C (243F). This allows the refrigerant gases to
cool and takes some of the load off the A/C compressor. When coolant
temperatures reach 112C (234F), the HVAC controller will return the
actuator to the previous setting.
Figure 5-16, Air

Distribution System
in RECIRC

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5-20
NORM A/C or MID Mode

The controller can select the Norm A/C or A/C mode automatically during
AUTO mode operation or the vehicle operator can manually select this
mode. In this mode of operation, the air exits the air distribution system
through the A/C (panel outlets with a slight bleed to the heater outlets
(Figure 5-17). On systems that utilize an AIR FLOW or MODE button, this
mode will be indicated as the MID setting.
Student Workbook
ASE 7 - HVAC
Systems
The inlet air door will be positioned in the outside air position unless the
RECIRC mode is manually selected. The controller will command the
compressor on when the outside air temperature is above approximately
40F (4C). This will cool and dehumidify the air entering the passenger
compartment. The controller will automatically maintain the temperature
(using the temperature door) and blower speed. The fan control switch
can be used to override or slightly adjust (system dependent) the
automatic control of the blower.
Figure 5-17, Air Distribution System in Norm A/C Mode

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5-21
HEATER or FLOOR Mode

The controller can select the HEATER mode automatically during AUTO
mode operation or the vehicle operator can manually select this mode. In
this mode of operation, the air exits the air distribution system through the
heater (floor) outlets with a slight bleed to the defrost outlets on some
applications (Figure 5-18). On systems that utilize an AIR FLOW or MODE
button, this mode will be indicated as the FLOOR setting.
Student Workbook
ASE 7 - HVAC
Systems
On most systems the inlet door will be positioned in the outside air
position unless the RECIRC mode is manually selected. On other
systems, the inlet air door is automatically placed in the recirculate
position in this mode (Aurora). Certain systems will command the
compressor on when the outside air temperature is above approximately
40F (4C). This will dehumidify the air entering the passenger
compartment. The controller will automatically maintain the temperature
and blower speed. The fan control switch can be used to override or
slightly adjust (system dependent) the automatic control of the blower.
Figure 5-18, Air Distribution System in HEATER Mode

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5-22
BI-LEVEL or MID/FLOOR Mode

The controller can select the BI-LEVEL mode automatically during AUTO
mode operation or the vehicle operator can manually select this mode.
In this mode of operation, the air exits the air distribution system through
the A/C and heater outlets (Figure 5-19). On systems that utilize an
AIR FLOW or MODE button, this mode will be indicated as the MID/
FLOOR setting.
Student Workbook
ASE 7 - HVAC
Systems
The inlet air door will be positioned in the outside air position unless the
RECIRC mode is manually selected. The compressor will be commanded
on by the controller when the outside air temperature is above
approximately 40F (4C). This will cool and dehumidify the air entering
the passenger compartment. The controller will automatically maintain the
temperature and blower speed. The fan control switch can be used to
override or slightly adjust (system dependent) the automatic control of the
blower.
Figure 5-19, Air Distribution System in BI-LEVEL Mode

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5-23
ECON / VENT Mode
Student Workbook
The ECON or VENT mode prevents the operation of the compressor and
positions the inlet air door in the outside air position. In this mode, the
controller tries to automatically maintain the SET temperature but it is
limited since the compressor will not operate. The interior air can only be
cooled to ambient air temperature. The controller still has the ability to
heat the air by positioning the temperature door to allow airflow through
the heater core. The controller will automatically select the outlet door
position unless manually selected by the vehicle operator (Figure 5-20).
ASE 7 - HVAC
Systems
The blower speed is also automatically controlled. The fan control switch
can be used to override or slightly adjust (system dependent) the
automatic control of the blower.
VENT and RECIRC cannot be selected at the same time, since they
command opposite inlet door positions. If VENT is selected when the
system is in RECIRC mode, the system will change to vent mode. When
the system is in DEFROST mode, pressing the VENT button will have no
effect on the system.
Figure 5-20, Air Distribution System in ECON/VENT Mode

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5-24
Re-Calibrating Actuators or HVAC Controller.

When an electronic actuator is replaced on a manual or automatic HVAC
control system, a re-calibration procedure may need to be performed to
allow the system to work properly. There are two procedures that are
generally used to re-calibrate the actuator. Examine the service
information to determine which method is to be used on a particular
vehicle.
Student Workbook
ASE 7 - HVAC
Systems
Calibration Procedure with a Scan Tool

Using the following steps to perform the calibration update:
1. Install a scan tool
2. Turn ON the ignition, with the engine OFF
3. With a scan tool, select Heating and Air Conditioning
4. Select Special Functions
5. Select Miscellaneous Test
6. Select HVAC Re-calibration
7. Follow scan tool prompts.
Calibration Procedure without a Scan Tool
1. Turn OFF the ignition.
2. Remove the battery positive voltage circuit fuse of the Instrument
Panel Control Module (HVAC Controller)
3. Wait 60 seconds.
4. Install the fuse
The module memory will not clear if the battery positive voltage circuit
fuse is installed in less than 60 seconds.

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5-25
Lesson 3: Special Operating Modes and Blower Controls

There are special situations where the controller changes its normal
blower and door control strategy. The controller will still maintain
automatic control of the blower but will adjust the blower speed and door
position to compensate for these situations.
The controller resumes normal automatic control when the conditions no
longer exist.
Student Workbook
ASE 7 - HVAC
Systems
Normal Purge:
In the normal purge mode, the controller delays blower operation and
positions the mode doors to direct any air blowing out of the heater
outlets. When the engine coolant temperature reaches approximately
126F, the blower will operate at a reduced speed for about 30 seconds to
further purge the air distribution system of moist air. The controller then
resumes normal system operation.
On certain systems (Cadillac E/K), the airflow is directed to the heater
outlets and then the blower is operated at low speed until normal system
operation can begin.
Normal system operation will occur after either of the following conditions
exists:
Program number command indicates cooling
Coolant temperature is greater then 97F (36C)
If neither of the above conditions exists within one to four minutes

(dependent on ambient temperature), the controller will automatically
resume normal operation.
Cold Purge:
In the cold purge mode, the controller positions the inlet air door to the
outside air position and directs air out the windshield outlet. This
decreases windshield fogging from the moist breath of vehicle occupants.
The blower motor operates at approximately 60% of its maximum speed
for several seconds. After cold purge is completed, the controller resumes
normal operation.
A/C Purge:
In the A/C purge mode, the controller positions the air doors to direct the
airflow out the heater outlets. This removes residual moisture from the air
distribution system when the controller determines refrigeration operation
is required to reach SET temperature. After A/C purge is completed, the
controller resumes normal operation. This mode will be by-passed if the
fan is operated in a manual mode or the vehicle operator selects a manual
mode.

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5-26
Instrument Panel Cluster (IPC) Cooling:
Student Workbook
In the IPC cooling mode, the controller will activate the blower and direct
air out of the A/C outlets when the interior temperature could cause
damage to the IPC components. The IPC cooling mode will be initiated
only when the following conditions are present:
ASE 7 - HVAC
Ignition is in the RUN position
Engine is not running or the HVAC system is OFF
Inside air temperature is above 125F (38C)
Blower override modes are not operating

Systems
Once this mode of operation is enabled, the minimum run time is four
minutes. The IPC cooling mode will be disabled if any of the following
occur:
Inside air temperature is below 121F (35C)
Engine is running or HVAC system is ON
Diagnostic mode is entered or a PCM-IPC Class 2 serial data fault is

present
Snow Ingestion Mode:

The snow ingestion mode of operation is used to reduce the possibility of
snow being pulled into the air distribution system and blown out of the
outlets. In the snow ingestion mode, the controller limits the blower to
7 volts until the coolant temperature exceeds approximately 100F for
three minutes. This mode is initiated if the operator selects DEFROST
mode when the ambient temperature is below 25F.
The reduced blower speed decreases the possibility of drawing snow
through the inlet air door. The 7-volt blower limit will be overridden if the
operator selects HI FAN during this mode.
Afterblow:
Afterblow is a feature that dries the evaporator core by operating the
blower motor after the engine is turned off. This reduces the amount of
microbial growth that can create undesirable odors. The vehicle does not
come equipped with the afterblow feature turned on. If the afterblow
feature is required due to an odor concern, it must be turned on by
reprogramming the HVAC control module, refer to in Vehicle Control
Systems.

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5-27
After the HVAC control module has been programmed for afterblow, the
following conditions must be met for afterblow to operate:
Student Workbook
1. The engine has been turned off for at least 30 minutes.
ASE 7 - HVAC
2. The ambient air temperature is at least 21C (70F).

Systems
3. The A/C compressor operated for more than 2 minutes.

4. The system voltage is at least 12 volts.
Once the above conditions have been met, the following sequence of
events will occur:
1. The blower motor will run for 20 seconds.
2. The blower motor will be off for 10 minutes.
3. The blower motor will run for an additional 20 seconds.

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5-28
Blower Control
Student Workbook
Blower speed is controlled by a blower control module, which follows

commands from the HVAC system controller. The controller determines
the correct blower speed using information from sensor inputs and the
control strategy within the controller. The controller provides the blower
control module with a pulse-width modulated signal that indicates the
desired blower speed. By using pulse-width modulation, the controller can
vary the average voltage 0 volt signal and commands the maximum
blower speed by providing 12 volts on the signal circuit. By increasing/
decreasing the average signal voltage, the controller can command the
blower control module to operate the blower at increased/decreased
speeds.
ASE 7 - HVAC
Systems
The blower control module also uses pulse-width modulation (PWM).

Based on the signal from the HVAC controller, the blower control module
applies a PWM signal on the blower motor circuit. By using pulse-width
modulation, the blower control module can control the average voltage
applied to the blower motor circuit, varying from 0 to 12 volts. The average
voltage that is applied to the circuit results in a specific current flow
through the blower, which controls the speed of the blower motor.
When an average of 4 volts is applied to the blower motor circuit, the
blower motor will operate at its slowest speed. The blower motor will
operate at its maximum speed when 12 volts is applied. Increasing the
average voltage above 4 volts produces an increase in the blower motor
speed. On some systems, the blower motor control voltage is also
provided to the HVAC controller as feedback to insure blower motor speed
stability and to allow the HVAC controller to detect failures in the blower
motor circuitry.
The blower can be operated in either manual fan mode or in automatic fan
mode. The fan speeds in manual mode are limited and remain constant
until the operator selects a different speed or AUTO mode. In AUTO fan
mode, the speed can be varied anywhere between the maximum and
minimum speeds. The blower motor speed in AUTO mode is determined
by the HVAC controller based on the following inputs:
Inside Air Temperature Sensor
Outlet Temperature Sensor
Ambient Air Temperature Sensor
Sun Load Sensor(s)
Engine Coolant Temperature
Vehicle Speed

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5-29
The controller uses these inputs and its internal control strategy to
generate a program number. This number (0 to 255) is used to determine
the blower speed for the heating and cooling requirements.
Student Workbook
ASE 7 - HVAC
Systems
Figure 5-21, Blower Module Control Circuit
Figure 5-22, Automatic HVAC Blower Control through Pulse Width Modulation

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5-30
Lesson 4: Sensors
Student Workbook
Various sensors are used by the HVAC controller to determine the correct
strategy for reaching and maintaining the SET temperature. The sensors
used include outside air temperature sensors, inside air temperature
sensors, outlet temperature sensors and sun load sensors. These are the
main inputs used by the HVAC controller; however, the controller also
uses powertrain inputs like the vehicle speed sensor to further adjust the
control strategy. There are even more inputs when considering
compressor controls. The following pages will focus on the temperature
and sun load sensors. Information on the inputs used for compressor
control is located in Module 3 "HVAC Controls".
ASE 7 - HVAC
Systems
Outside Air Temperature Sensor

The outside air temperature sensor, also called the ambient air
temperature sensor, is an NTC thermistor. It is located at the front of the
vehicle near the bumper or grill area. The outside air temperature sensor
provides the HVAC controller with an input signal based on surrounding air
temperature. The controller uses this input in determining heating and
cooling requirements.
The operation of the ambient air temperature sensor is similar to that of
the outlet air temperature sensors. A 5-volt reference signal is sent from
the controller to the outside air temperature sensor over the input circuit.
A thermistor inside the sensor varies the voltage. The HVAC controller
measures the voltage drop across the sensor to determine the resistance
of the sensor and to calculate the temperature. As the ambient air
temperature increases, resistance decreases. The reference low provides
ground to the sensor.
Since the sensor is mounted under the hood it can be affected by city
traffic, idling and hot engine restarts. A temperature memory feature is
used in the controller ambient software programming to help provide
greater accuracy under engine restart conditions. If the engine coolant
temperature is not more the 10C (18F) above the ambient air
temperature sensor reading, or if the engine has not been started in two
hours, the actual outside air temperature is displayed. This is the last
displayed temperature sensed when the engine was operating at vehicle
speeds greater then 16 km/h (10 mph).
The ambient air temperature displayed may be allowed to increase, but
only after a built-in 300-second time delay which allows for outside air to
cool the sensor. The delay starts after the vehicle reaches 10 mph. If the
sensor reading is ever less than the displayed value, then the ambient air
temperature changes are displayed as rapidly as possible.

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5-31
Student Workbook
ASE 7 - HVAC
Systems
Figure 5-23, Outside Air Temperature Sensor Location (Radiator Support Bracket)
Figure 5-24, Outside Air Temperature Sensor (Ambient)

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5-32
Inside Air Temperature Sensor

The inside air temperature sensor is an NTC thermistor. It is located in
the dashboard within a small grill-like opening. It may also be located in
the headliner or near the driver's door. The sensor provides the HVAC
controller with a sample of the inside air temperature. The controller uses
this input to determine heating and cooling requirements during the first
10 to 15 minutes of automatic control.
Student Workbook
ASE 7 - HVAC
Systems
The operation of the inside air temperature sensor is similar to that of the
outlet air temperature sensors. At HVAC system startup, the primary input
for determining passenger compartment temperature is the inside air
temperature sensor. However, AFTER a number of minutes, the controller
uses the outlet temperature sensors as the primary inputs.
To provide accurate sensing of the car interior temperature, a small
amount of air is drawn into the inside sensor housing and passed over the
thermistor. This air movement is accomplished by two means a small
motor or the use of an aspirator mounted on the HVAC module box.
The aspirator is a tube-within-a-tube arrangement. A small portion of the
main air stream within the module box is discharged through the main
outer tube. This exiting air stream causes a suction at the end of the inner
tube so that compartment air is drawn into the inside sensor housing and
flows out the inner tube at the aspirator.
A substitute temperature value of approximately 75F (24C) is used when
this sensor fails to allow the HVAC system to continue to operate.
Figure 5-25, Inside Air Temperature Sensor and Aspirator

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5-33
Upper (A/C) and Lower (Heater) Outlet Temperature Sensors
Student Workbook
The upper A/C and lower heater outlet temperature sensors are NTC
thermistors. The upper outlet sensor is located in the dashboard center
vent duct near the outlet. The lower outlet sensor is located in the heater
duct near the outlet.
ASE 7 - HVAC
The upper and lower outlet temperature sensors are used to monitor the
discharge temperatures from the heater and A/C outlets.

Systems
After some time -10 to 15 minutes - the HVAC controller uses these
sensor inputs as the primary inside temperature sensors.
On dual zone systems, upper and lower sensors are use on each side of
the dash to monitor temperature on the driver and passenger sides of the
vehicle.
The sensors react to the temperature with a resistance change. This
causes a change in voltage to the HVAC controller that reflects the
temperature values at each sensor.
Based on this voltage signal, the HVAC controller determines heating and/
or cooling requirements and makes adjustments accordingly. The
controller adjusts the position of the temperature door to meet the set
temperature.
Figure 5-26, Inside and Outlet Air Temperature Sensor Circuit
Figure 5-27, Outlet Air Temperature Sensor

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5-34
Solar (Sunload) Sensor
Student Workbook
The sun load sensor is a photoconductive diode. It is designed to allow

reverse current flow when exposed to light. It is located on the upper
surface of the dashboard near the windshield. Dual zone automatic HVAC
systems utilize two sensors, one on side of the dashboard.
ASE 7 - HVAC
Sun load sensors provide the controller with information on the amount of
sunlight that is entering the passenger compartment so the controller can
adjust the cooling requirement accordingly.

Systems
When more sunlight enters the passenger compartment, the heat load on
the system increases due to the "greenhouse effect."
The sun load sensor sends a signal to the HVAC controller based on the
intensity of the light. Based on this signal, the HVAC controller makes
minor adjustments to the blower speed and the temperature and mode
doors to compensate for the added heat load.
It is important to note that the operation of the sun load sensor(s) will be
affected if covered. This will also impact how the controller determines the
cooling requirements. Always make sure the solar sensors are not
obstructed when diagnosing an automatic HVAC system.
Certain applications (Catera) will use a solar/twilight sensor (four-wire
sensor). This is a photoelectric cell, which means it will produce voltage
when exposed to light. On these applications, the photoelectric cell
provides two inputs to the HVAC controller. One input is used for solar
load and the other is used for the twilight sentinel.
Figure 5-28, Solar (Sunload) Sensor

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5-35
Lesson 5: Automatic Dual Zone System

Automatic dual zone systems operate like single zone automatic systems.
Like the manual dual zone systems, separate ductwork and doors are
utilized for the passenger and driver side of the HVAC module. However,
there are more sensors.
There are four outlet (duct) sensors, two solar sensors, one inside air
temperature sensor, and one ambient air temperature sensor.
Student Workbook
ASE 7 - HVAC
Systems
Also, the passenger control panel on the automatic dual zone HVAC
control systems allows manual control over the passenger side
temperature door.
The passenger side temperature control is located on either the
passenger side of the main controls or on the dashboard or on the
passenger door armrest.
Mode doors on automatic dual zone systems can be controlled by either
vacuum solenoids or electrical motors. Temperature doors are controlled
by electrical motors. The motors can be either old type five wire motors or
new type five-wire motors.
Figure 5-29, Automatic Dual Zone System with Old and New Style Motors

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5-36
The passenger or driver side temperature control sends signals to the

HVAC controller. The HVAC controller will generate two program numbers
(0-255) that will be used to command their respective doors to the proper
position. Once the system temperature is set all functions of blower, mode
door and temperature door will be adjusted to maintained the
compartment temperature. Temperature changes are monitored through
the outlet, ambient, and inside.
Student Workbook
ASE 7 - HVAC
Systems
Changes in solar sensor readings generally result in changes to blower

speed first to provide added air conditioning in the vehicle. If further
cooling is needed then mode and temperature doors position adjustments
will occur.
Figure 5-30, Automatic Dual Zone System with Multiple Sensors
Note:
When diagnosing battery draws on cars/trucks equipped with the
automatic dual zone HVAC controls (RPO CJ2), technicians should keep
in mind that the control head does not completely "go to sleep" until after
150-250 minutes, or up to 4- hours, from when the ignition key is turned
OFF. This is a normal condition. In these cases, DO NOT replace the
control head.

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5-37
Lesson 6: Automatic Rear HVAC System

The Automatic HVAC systems can have the option of being configured
with either a manual or automatic (rear) auxiliary system. This lesson will
discuss a variety of GM SUV's and luxury vehicles utilizing the automatic
rear HVAC systems.
Student Workbook
ASE 7 - HVAC
Systems
Suburban, Escalade, Denali, Avalanche Automatic Rear HVAC

The number of auxiliary HVAC controls on these vehicles is dependent
upon whether or not the vehicle is equipped with a sunroof. An automatic
auxiliary HVAC system is only available without a sunroof. The automatic
primary and auxiliary HVAC systems communicate using keyboard data
display (KDD) protocol. The automatic primary system communicates
with the rear auxiliary HVAC control module. It can be identified by the
wording Computer Climate Control on the front faceplate of the auxiliary
control modules.
The front auxiliary HVAC control assembly provides inputs to the rear
auxiliary HVAC control module. It is located in the overhead console so
that front seat occupants can control auxiliary HVAC operation. This
assembly provides blower, air delivery mode, air temperature settings and
control of which unit will operate the auxiliary HVAC system. When the
REAR position is selected, inputs from this control assembly will not be
processed by the rear auxiliary HVAC control module. Only the rear seat
occupants can control the HVAC settings. When (front auxiliary) OFF
position is selected the auxiliary system is inoperative.
Figure 5-31, Automatic Rear HVAC Control Head (2003 Suburban)

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5-38
When AUTO is selected on the front auxiliary HVAC assembly, the rear
auxiliary HVAC control module processes and controls all aspects of the
automatic auxiliary HVAC system. The system receives inputs from the
auxiliary upper air temperature sensor, auxiliary lower air temperature
sensor, infrared temperature sensor, and feed back signals from the
auxiliary mode actuator and the auxiliary air temperature actuator. Inputs
from the front auxiliary HVAC control assembly also plays a part in rear
HVAC operations. The outputs are the auxiliary air temperature actuator,
auxiliary mode actuator, auxiliary blower motor control processor and data
communication with the HVAC control module.
Student Workbook
ASE 7 - HVAC
Systems
The upper and lower auxiliary air temperature sensors are Negative
temperature coefficient thermistors. When the air temperature is warm,
the sensor resistance and signal voltage is low and vice versa when the
temperature is cool. A fixed resistance inside the rear auxiliary control
module makes the 5-volt signal circuit a series circuit.
The rear control module monitors the voltage drop of the circuit, which is
needed to calculate the air temperature. The ground for the upper and
lower auxiliary air temperature sensors are provided by the low reference
circuit.
The rear auxiliary HVAC control module will use a default value for the
upper and lower auxiliary air temperature signal if there is a fault with the
input. The rear auxiliary HVAC control module will use a default to ensure
auxiliary operation is stilled performed. The scan tool value will be the
actual reading of the signal circuit. This means if signal circuit is shorted to
a ground then the scan tool will read 0 counts. If the signal circuit is more
than 5 volts than it will read 255 counts.
Figure 5-32, Automatic Rear HVAC System (Suburban)

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5-39
Figure 5-33, Infrared Sensor used on Automatic

Rear HVAC System (2002, Suburban)
The auxiliary inside air

temperature sensor is an
infrared sensor. This
component is integral to the
rear auxiliary HVAC control
module. There is a lens on
the front faceplate that
must not be cleaned or
contaminated. The sensor
can detect the amount of
heat in the rear of the
vehicle.
Student Workbook
ASE 7 - HVAC
Systems
If the sensor lens is covered or contaminated the sensor cannot make a

proper indication of heat. The sensor does not set a DTC. The sensor
helps in making the proper automatic calculations to position the auxiliary
mode and temperature doors. Starting in 2003, the infrared sensor was
replaced with a thermistor design.
The auxiliary air temperature and mode actuator are 5-volt style
components that uses the 0-5 volt reference circuit. As the actuator
moves the feedback voltage on the door is monitored by the auxiliary
HVAC control module. The temperature door position is determined by the
inputs of the duct and inside temperature sensors.
The vehicle operator determines the mode setting by placing a mode
switch in a desired position. Only upper and lower vent positions are
available in the rear of the vehicle.
When the HVAC system is in AUTO setting the interior temperature is
maintained by controlling the blower motor, air temperature and mode
setting. We have discussed the air temperature controls but a major
component that affects overall comfort is the blower motor.
The auxiliary blower motor circulates the air at the rear of the vehicle. The
auxiliary blower motor can be controlled by either the auxiliary HVAC
controls. With the setting of the front auxiliary control set to REAR
position, the rear passenger determines the blower motor's speed by
placing a blower motor switch in a desired speed position or by selecting
automatic operation.
When any blower speed is selected on either of the auxiliary controls, the
modules send a pulse width modulated (PWM) signal to the auxiliary
blower. The speed remains constant until a new speed is selected. In
automatic operation, the auxiliary HVAC module will determine what
auxiliary blower speed is necessary in order to maintain desired
temperatures. At startup in colder temperatures, the auxiliary blower
motor will not begin operation at the same time as the primary blower
motor. Warm coolant is circulated to the auxiliary heater core before the
blower motor begins operating.

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5-40
Lesson 7: Steering Wheel Controls

Steering wheel controls were added to some vehicles for driver safety and
convenience in operating the HVAC or radio systems. Steering wheel
controls were first introduced at a time when vehicles did not have
airbags. The introduction of airbags made it necessary to adapt digital
steering wheel controls of the past to a different technology. As a result,
analog steering wheel controls are now typically found on airbag equipped
vehicles. Analog steering wheel controls systems are used to provide
communication from the steering wheel to the HVAC controller by means
of hardwire connections rather then the complex designs of the past.
Student Workbook
ASE 7 - HVAC
Systems
Figure 5-34, Analog Steering Control
The analog steering wheel controls are very similarly configured across
vehicles because of the airbag limitations. All analog steering wheel
control systems, commonly called SWC systems, allow the driver to
change fan speed and the temperature settings. The steering wheel
control consists of buttons mounted on either side of the airbag. In some
vehicles, an interface box is used for communication on the E & C data
line. In other vehicles, the radio is used as the interface.

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5-41
A single line is used to carry the analog voltage from the button pad to the
interface box or directly to the radio control head or to the dash integration
module (DIM). Each button operates a switch that provides a different
voltage drop. The amount of voltage drop depends on the number of
resistors placed in the series circuit (Figure 5-35). Current flows through
the resistors in a series through the SIR coil to the interface (DIM) or radio
which in turn sends a command to the HVAC controller through the class
2 bus or E & C data line.
Student Workbook
ASE 7 - HVAC
Systems
The HVAC controller carries out the command as if it had come from the
instrument panel control head.
Figure 5-35, Analog Steering Wheel Control Circuit

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5-42
The digital systems use a very elaborate optical-electrical network to

transfer signals from the steering wheel to the E&C entertainment and
convenience data line. When a selection is made on the steering control
head, a signal is sent to the cancel cam assembly.
Student Workbook
ASE 7 - HVAC
Systems
Figure 5-36, Digital Steering Control
This triggers the appropriate optical emitter signal. The receiver transistor
then sends this signal to the heater-A/C and radio interface module, which
is transmitted over the E & C data line.
Figure 5-37, Digital Steering Wheel Control Circuit (Older System)

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5-43
Lesson 8: Automatic HVAC System Diagnosis

General Motors provides specific A/C system "Strategy Based Diagnostic"
charts and procedures for their various models and model years. These
procedures should always be referred to during system diagnosis and
repair because of the many changes that may occur by vehicle model,
manufacturing year or A/C system content and configuration. Because of
these varied systems no universal or standard A/C system diagnostic
procedure exists. Yet a properly trained service technician can develop a
logical diagnostic strategy by answering three simple questions. These
include:
Student Workbook
ASE 7 - HVAC
Systems
1. What are the problem symptoms? This is what has indicated a

problem with system operation or component function. Usually, a
customer concern with system performance indicates the problem
symptoms. If not, the technician should request more information.
2. What caused the problem symptoms? This involves using certain
diagnostic procedures to identify the cause of the problem. These may
range from the technician's knowledge of common system failures and
component malfunctions, through a visual inspection of the system for
leaks and noise or odor, to specific system tests for control functions,
sufficient cooling and overall performance.
3. How can the problem be fixed? This usually involves the adjustment,
repair, or replacement of one or more components of the system. By
accurately diagnosing the root cause of a given problem symptom, the
service technician should be able to efficiently correct the problem.

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5-44
Using a "strategy-based diagnostic thought process," the service

technician proceeds from verifying the customer concern, through making
quick checks, to performing more detailed diagnostic system checks
similar to that shown in the chart in Figure 5-38. This process includes
considering that the cause of the A/C performance concern may be traced
to one or more of the three HVAC sub-systems. Once a cause has been
identified, the technician can then make necessary system repairs and
verify that the condition has been eliminated.
Student Workbook
ASE 7 - HVAC
Systems
Figure 5-38, Strategy Based Diagnosis Chart
To troubleshoot problems with HVAC air distribution system controls,

several standard charts can serve as a basic foundation for more specific
system testing. These include a "Diagnostic Starting Point" Chart (Heating, Ventilation and Air Conditioning), a "Diagnostic System Check"
Chart and a Symptoms Diagnosis Chart.

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5-45
The A/C system visual inspection and diagnostic charts can identify
conditions within the air-delivery system. For instance, insufficient
discharge air may indicate conditions within the blower motor or fan
system. A malfunctioning mode control selector, sticking or damaged air
doors/valves, or restrictions in the outlets themselves, may cause
improper outlet selection. Not achieving desired temperature settings
might be caused by an inoperative temperature door valve, sensor or
other controls.
Student Workbook
ASE 7 - HVAC
Systems
Vehicle "Service Information" (SI) contains diagnostic and service

procedures for malfunctions in the air-delivery system. Most often, these
conditions can be traced to either electrical control causes and, more
rarely, mechanical malfunctions within the HVAC module.
Proper performance of the cooling and air-delivery sub-systems in an
HVAC system is essential for proper operation of the refrigeration
subsystem.
Diagnostic Starting Point Chart - Heating, Ventilation and Air
Conditioning
The Heating, Ventilation and Air Conditioning (HVAC) system is divided
into three sections. The first, Heating, Ventilation and Air Conditioning, has
all procedures that pertain to a HVAC component or function that are not
specifically associated with an automatic or manual control system. The
second, HVAC Systems-Manual, has all procedures specific to the manual
control system. The third, HVAC Systems-Automatic, has the entire
procedures specific to the automatic control system.
For systems with DTCs, begin the system diagnosis with the following
procedures:
Diagnostic System Check - HVAC Systems - Manual in HVAC

Systems-Manual
Diagnostic System Check - HVAC Systems - Automatic in HVAC

Systems-Automatic
The Diagnostic System Check will provide the following information:
The identification of the control modules, which command the system.
The ability of the control modules to communicate through the Class 2

serial data circuit.
The use of the Diagnostic System Check will identify and lead the
technician to the correct diagnostic procedure.

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5-46
Review the Description and Operation information to help you determine

the correct symptom diagnostic procedure when a malfunction exists.
Reviewing the Description and Operation information will also help you
determine if the condition described by the customer is normal operation.
The HVAC Description and Operation information is divided into:
Air Delivery Description and Operation in HVAC Systems-Manual
Air Temperature Description and Operation in HVAC SystemsManual
Air Delivery Description and Operation in HVAC Systems-Automatic
Air Temperature Description and Operation in HVAC SystemsAutomatic
Student Workbook
ASE 7 - HVAC
Systems
The Air Delivery Description and Operation contains the following topics:
HVAC Control Components
Air Speed
Air Distribution
Recirculation Operation
Automatic Operation
Diagnostic System Check Chart - HVAC Systems - Automatic

Test Description
The number(s) below refer to the step number(s) on the diagnostic table.
3. Lack of communication may be due to a partial malfunction of the
class 2 serial data circuit or due to a total malfunction of the class 2
serial data circuit. The specified procedure will determine the
particular condition.
5. Determine if the Driver Door Module, Powertrain Control Module,
Instrument Panel Integration Module or Dash Integration Module has
set DTCs, which may affect HVAC operation, are present.
6. The presence of DTCs, which begin, with "U" indicate some other
module is not communicating. The specified procedure will compile all
the available information before tests are performed.
7. Answer Yes if the first three characters of the DTC name begin with
B10; regardless of the last two characters. If a B1000 code is set,
answer "No" to the question.
8. Be sure to follow the diagnostic table for B1000 in the HVAC SystemsAutomatic section. Do not use the table in Body Control System.
Check History Diagnostic Trouble Code(s) on the scan tool before
proceeding.

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5-47
Step
Action
Yes
No
Go to Step 2
Go to Diagnostic
Starting Point - Heating,
Ventilation and Air
Conditioning in Heating,
Ventilation and Air
Conditioning
Go to Step 3
Go to Scan Tool Does

Not Power Up in Data
Link Communications
Go to Step 4
Go to Scan Tool Does

Not Communicate with
Class 2 Device in Data
Link Communications
Go to Step 5
Go to Power Mode
Mismatch in Body
Control System
Did you review A Diagnostic

Starting Point - Heating,
Ventilation and Air
Conditioning?
Install a scan tool.

2
Does the scan tool power up?
Student Workbook
ASE 7 - HVAC
Systems
1. Turn ON the ignition, with

the engine OFF.
2. Attempt to establish
communication with the
following control
modules:
o Driver Door
Module
o Powertrain Control
Module
o Instrument Panel
Integration Module
o Dash Integration
Module
Does the scan tool
communicate with the control
modules?
Important
The engine may start during the
following step. Turn OFF the
engine as soon as you have
observed the Crank power
mode.
1. Access the Class 2

Power Mode in the
Diagnostic Circuit Check
on the scan tool.
2. Rotate the ignition switch
through all positions
while observing the
ignition switch power
mode parameter.

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5-48
Student Workbook
Select the display DTCs

function on the scan tool for the
following control modules:
ASE 7 - HVAC
Driver Door Module

Powertrain Control
Module
Instrument Panel
Integration Module
Dash Integration Module

Systems
Go to Step 6
Go to Symptoms HVAC Systems Automatic
Go to Scan Tool Does Not

Communicate with Class 2
Device in Data Link
Communications
Go to Step 7
Go to Diagnostic Trouble Code

(DTC) List in Body Control System
Go to Step 8
Does the scan tool display DTC

8
B1327?

(DTC) List in Engine Electrical
Go to Step 9
Does the scan tool display any

9 DTCs, which are not associated
with the HVAC system?

(DTC) List in Engine Controls 3.8 L
Go to Diagnostic
Trouble Code
(DTC) List

DTCs?
6

DTCs, which begin with a "U"?
Does the scan tool display DTC

B10XX, except B1000?

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5-49
Symptoms Chart - HVAC Systems - Automatic
Student Workbook
Important
The following steps must be completed before using the symptom tables.
ASE 7 - HVAC
1. Perform the Diagnostic System Check - HVAC Systems - Automatic

before using the Symptom Tables in order to verify that all of the
following are true:

Systems
There are no DTCs set.
The control modules can communicate via the serial data link.
2. Review the system operation in order to familiarize yourself with the

system functions. Refer to:
Air Delivery Description and Operation
Air Temperature Description and Operation
Visual/Physical Inspection
Inspect for aftermarket devices, which could affect the operation of the
HVAC System. Refer to Checking Aftermarket Accessories in Wiring
Systems.
Inspect the easily accessible or visible system components for obvious

damage or conditions, which could cause the symptom.
Verify the A/C compressor clutch turns freely and is not seized.
Verify that the customer is using the correct key to enable

personalization and is not inadvertently activating steering wheel or
passenger HVAC controls, if equipped.
The A/C compressor will not operate in cold ambient air temperatures.
Refer to Air Temperature Description and Operation.
The following conditions may cause window fogging:

Wet carpet or mats
High humidity
Interior water leak
Blocked A/C evaporator drain tube
Maximum passenger capacity
Blocked body pressure relief valves
Inspect the air distribution system for causes of reduced air flow:
Obstructed or dirty passenger compartment air filter, if equipped
Blocked or damaged air inlet or outlet vents

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5-50
Intermittent
Student Workbook
Faulty electrical connections or wiring may be the cause of intermittent

conditions. Refer to Testing for Intermittent and Poor Connections in
Wiring Systems.
ASE 7 - HVAC
Symptom List

Systems
Refer to a symptom diagnostic procedure from the following list in order to

diagnose the symptom:
HVAC Compressor Clutch Does Not Engage
HVAC Compressor Clutch Does Not Disengage
Blower Motor Always On
Blower Motor Inoperative
Blower Motor Malfunction
Temperature Variation Between Driver and Passenger Outlets
Control Head Illumination/Display Does Not Operate Properly
Too Hot in Vehicle
Too Cold in Vehicle
Outside Air Temperature Display Inaccurate or Inoperative
Steering Wheel Controls Inoperative
Passenger HVAC Control Does Not Operate Properly
Air Delivery Improper
Air Conditioning (A/C) System Does Not Maintain Set Temperature
Air Recirculation Malfunction
Afterblow Enable Procedure
Leak Testing in Heating, Ventilation and Air Conditioning
Noise Diagnosis - Blower Motor in Heating, Ventilation and Air

Conditioning
Noise Diagnosis - Air Conditioning (A/C) System in Heating,

Ventilation and Air Conditioning
Noise Diagnosis - HVAC Module in Heating, Ventilation and Air

Conditioning
Odor Diagnosis in Heating, Ventilation and Air Conditioning

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5-51
Module #5 Post-test
Student Workbook
Read each question carefully and choose the correct response.

1. Which of the following is a true statement about automatic HVAC
control systems:
a. Sensors provide all the inputs.
b. The compressor does not run in all modes.
ASE 7 - HVAC
Systems
c. The operator provides all input.

d. The operator selects blower speed.
2. Which of the following is located on top of the dashboard:
a. Sun Load Sensor
b. Outlet Air Temperature Sensor
c. Inside Air temperature Sensor
d. Ambient Air Sensor
3. After the cold purge mode is complete, the HVAC Controller
automatically switches to:
a. The A/C Purge mode
b. The IPC Cooling mode
c. Normal Operation
d. The Defrost mode
4. In the manual mode of automatic HVAC control systems:
a. Fan speed will vary according to various speeds.
b. Fan speed will vary according to temperature sensor inputs.
c. The position of the temperature door will vary once a temperature
is selected.
d. The HVAC controller will try to maintain set temperature as much
as possible.

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5-52
5. The primary function of outlet temperature sensors is to:
Student Workbook
a. Prevent evaporator freeze up.

b. Monitor the discharge temperature from the heater and A/C duct
outlets.
c. Measure sunlight intensity.
d. Determine if the outside temperature exceeds the set temperature.
ASE 7 - HVAC
Systems
6. When a customer sets the temperature in an automatic HVAC control

system, the system can automatically regulate:
a. Inside air temperature if the programmed number does not exceed
100oF.
b. Inside air temperature only if the programmed number exceeds
100oF.
c. Inside air temperature only if the outside air temperature is between
65o and 85oF.
d. Inside air temperature from 65o to 85oF regardless of outside air
temperature.
7. In analog steering wheel controls:
a. The amount of voltage drop depends on the number of resistors
placed in the series circuit.
b. The voltage drop depends on the number of resistors placed in
parallel.
c. A very elaborate optical-electrical network is used for signal
transfer.
d. Communication from the steering wheel to the base of the steering
column occurs without hardwire connections.
8. Which of the following best represents the difference between single
zone and dual zone automatic HVAC control systems?
a. Number of sensors.
b. Number of mode doors.
c. Number of air inlet doors.
d. Number of air outlets.

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5-53
9. In analog steering wheel controls, signals are transferred by means of:
Student Workbook
a. Optical signals.
b. Radio waves.
ASE 7 - HVAC
c. Optical/ Electrical signals.

Systems
d. Electrical signals.
10. Analog steering wheel controls use different __________ as signals to
control the HVAC settings.
a. Radio waves.
b. Optical pulses.
c. Voltage drops.
d. Current flows.
11. HVAC controllers are normally located in the
a. PCM
b. Vehicle engine compartment
c. HVAC module box
d. Vehicle instrument panel
12. What is the primary function of the sun load sensor?
a. To provide the controller with information about the temperature
inside the vehicle.
b. To allow the controller to adjust for the amount of sunlight entering
the vehicle.
c. To provide the controller with information about the ambient
temperature.
d. To provide the controller with information about instrument panel
overheating.
13. Which of the following statements best describes the auto mode?
a. The customer can control compression operation.
b. Sensors provide the only inputs.
c. The only parameter the customer can control is temperature.
d. The customer can control blower speed.

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5-54
14. Pulse Width Modulated (PWM) blower speed will:
Student Workbook
a. vary the average voltage signal from 13 to 15 volts

b. decrease blower speed with an increase in PWM
ASE 7 - HVAC
c. operate the blower at four predetermined speeds

Systems
d. increase blower speed with an increase in PWM

15. The reference voltage for the in-car temperature sensors is:
a. 0-12 volt, variable
b. 5 volt
c. 8 volt
d. 12 volt
16. Based on vehicle operator settings, the controller selects a program
number between _________ to maintain set temperature.
a. 0 and 500
b. 0 and 255
c. 1 and 10
d. 1 and 125
17.When OFF is selected on an automatic HVAC system, the:
a. blower motor will operate
b. compressor will operate
c. controller remains active
d. set temperature is ignored by the controller
18. After 10 to 15 minutes of AUTO operation, the HVAC controller uses
which temperature sensor as the primary input to control SET
temperature.
a. Inside air temperature sensor
b. Outside air temperature sensor
c. Outlet temperature sensor(s)
d. Solar sensor(s)

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5-55
19. Automatic dual zone systems will have as many as __________

temperature sensors:
Student Workbook
a. 2
ASE 7 - HVAC
b. 3

Systems
c. 4
d. 5
20. Automatic rear HVAC systems (Suburban) can use a number of
__________ sensors to control temperature of the rear seating area.
a. inside temperature
b. infrared
c. outlet sensor
d. all of the above
21.When an actuator or HVAC controller is replaced on an automatic
HVAC system, the system must be _____________.
a. reprogrammed
b. recalibrated
c. performance checked
d. checked for DTC's
22. If the in-car air temperature sensor fails, the default temperature value
used by the HVAC controller:
a. is 65F
b. is 75F
c. reverts to manual operation
d. shuts down
23. On a___________ wire actuator motor, the HVAC controller counts the
commutator segment pulses and converts the them to a. 0-255 binary
signal.
a. two
b. three
c. five
d. film

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5-56
Exercise Lesson 1 & 2

Automatic HVAC Systems Overview
Directions: Use module 5 of the student workbook to answer the
following questions.
Student Workbook
ASE 7 - HVAC
Systems
1. In AUTO Mode, what is the temperature range that the HVAC controller
will try to reach and maintain?
Page: ______
________________________________________
_______________________________________________________
2. Do any automatic HVAC systems use vacuum to control the
temperature door?
Page: ______
________________________________________
_______________________________________________________
3. The HVAC controller uses the program number to determine the
control of which HVAC system components in AUTO mode?
Page: ______
________________________________________
_______________________________________________________
4. In full manual control, what components of the HVAC system are still
under the automatic control the controller?
Page: ______
________________________________________
_______________________________________________________
5. In OFF mode, can the controller operate any of the components of the
HVAC system? If yes, which components?
Page: ______
________________________________________
_______________________________________________________
6. Why is the RECIRC mode not available in DEFROST?
Page: ______
________________________________________
_______________________________________________________

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5-57
Exercise Lesson 2
Modes of Operation Program Number
Student Workbook
ASE 7 - HVAC
Directions: Use the classroom vehicle to answer the following questions.

Vehicle Information:

Systems
Make: ________________
Model: ________________
Year: _________________
1. What is the range of the program number on this vehicle (0-100% or 0255 counts)? ___________________________________________
2. What does a program number of 0% or 0 counts indicate (full cold, full
hot or mid-position)? _____________________________________
3. What does a program number of 100% or 255 counts indicate (full
cold, full hot or mid-position)? ______________________________
4. In AUTO mode, what is the status of the following if 60F (15C) is
selected as the desired temperature:
Program number: ________________________________________
Airflow path: ____________________________________________
Blower speed: __________________________________________
Temperature door position: ________________________________
5. In AUTO mode, what is the status of the following if 90F (32C) is
selected as the desired temperature:
Program number: _______________________________________
Airflow path: ____________________________________________
Blower speed: __________________________________________

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5-58
6. What will be the status of the following if the selected temperature and
the in-car temperature are equal?
Student Workbook
Program number: ________________________________________
ASE 7 - HVAC
Airflow path: ____________________________________________

Systems
Blower speed: __________________________________________

7. If an air door (mode or temperature) is inoperative or misadjusted, will
it have an affect on the program number? Why or why not?
______________________________________________________
______________________________________________________
8. Is there any adjustment procedures that must be followed after a
motor/actuator is replaced? If yes, what are the procedures?
______________________________________________________
______________________________________________________
9. Insert in the table both the commanded counts and volts (displayed on
the TECH 2) for the doors in the modes of operation (some systems
will use units other than volts or counts):
10. In the table below, record both the commanded counts and volts for
the temperature door(s) with the system in AUTO mode. If the vehicle
is not Dual Zone, do not fill out the passenger temperature door
information.

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5-59
11. If the commanded counts, volts or other units does not match the
actual counts or volts, what could be the malfunction?
Student Workbook
______________________________________________________
ASE 7 - HVAC
______________________________________________________

Systems
12. Turn the key to the ON position with the engine off. Set the desired
temperature to 72F. Insert, in the table below, the values for the
temperature sensors. If the vehicle does not have a specific sensor or
information, insert N/A in the table.
13.Start the engine and turn the HVAC system to AUTO mode with a SET
temperature of 78F. View the counts, volts or other units for the doors.
Based on this information what mode of operation is the HVAC system
commanding?
______________________________________________________
______________________________________________________
14. Is it commanding heating or cooling (approximate)?
______________________________________________________
______________________________________________________

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5-60
Exercise Lesson 3
Student Workbook
Special Operating Modes and Blower Control

1. What is the purpose of the A/C Purge mode?
Page: _______
________________________________________
ASE 7 - HVAC
Systems
_______________________________________________________
2. How does the pulse-width modulation from the blower module control
the speed of the blower motor?
Page: _______
________________________________________
_______________________________________________________
3. Why does the controller filter the signal from the outside air
temperature sensor?
Page: _______
________________________________________
_______________________________________________________
4. What is the purpose of AFTERBLOW?
Page: _______
________________________________________
_______________________________________________________
5. What is the purpose of A/C Purge mode?
Page: _______
________________________________________
_______________________________________________________

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5-61
Exercise Lesson 4
Automatic HVAC Service Information
Student Workbook
Directions: Answer the following questions using the Service Information

(SI) on-line. The service information may not have answers to all of the
questions.
ASE 7 - HVAC
Make: ________________

Systems
Model: ________________
Year: _________________
1. Place a check mark next to each sensor that is used on this vehicle:
In-car sensor
Outside sensor
Upper right duct sensor
Upper left duct sensor
Lower right duct sensor
Lower left duct sensor
Infrared sensor
Sunload sensor
2. How does the microprocessor determine when to update the outside

air temperature display on the control head? __________________
______________________________________________________
______________________________________________________
3. How is the outside air temperature display on the control head
manually updated on this vehicle? __________________________
______________________________________________________
______________________________________________________
4. What component and circuit provides ECT DATA to the HVAC
controller? _____________________________________________
5. The control head uses what data line to transfer information to the
PCM? _________________________________________________
6 What is the Service Information (SI) number that contains the
procedures to recalibrate the HVAC air temperature door?
______________________________________________________

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5-62
7. How many mode (inlet and outlet) door motors does this vehicle have?
______________________________________________________
8. During the diagnosis of a vehicle (customer concern: Incorrect airflow),
you notice that the airflow is being directed towards the floor. The
commanded HTR/DEF/AC door count is 243. The actual door count is
123 and the program number is 255. What could be the fault?
Student Workbook
ASE 7 - HVAC
Systems
______________________________________________________
______________________________________________________
______________________________________________________

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5-63
Student Workbook
Exercise Lesson 8
Automatic HVAC Controls Diagnosis
Directions:
ASE 7 - HVAC
Answer the following questions using the (SI) Service

Information and a systematic procedure of Strategy Based
Diagnosis. Diagnose and repair the following vehicle
problem that has been set-up by your instructor.
Customer Concern:

Systems
Owner of a 2002 S-10 Blazer 4WD

No cold air for several days
Blows only warm air
Step 1: Verify Customer Concern(s)

Does cold air come out of vent outlets?
YES
NO
Does Temperature of air change when setting is changed? YES
NO
Is the problem intermediate?
YES
NO
YES
NO
Step 2: Preliminary Checks

Inspect the fuses and electrical connections.
Any problems found?
If so, describe problem.______________________________________

_________________________________________________________
_________________________________________________________

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5-64
Step 3: Perform Diagnostic System Check
Student Workbook
Perform a diagnostic system check as outlined in service information.

Confirm system for proper and improper operation. You already know that
the system blows no cold air.
ASE 7 - HVAC
Connect a scan tool to the DLC

Any trouble code(s) found?
YES
NO

Systems
If so, what code(s) was found? ________________________________

According to the diagnostic system check, where would you proceed
next? ____________________________________________________
________________________________________________________
Step 4: Check for Bulletins
Check for bulletins using Service Information (SI).
Were any bulletins found related to the customers concern? YES
NO
If so, what bulletin? _________________________________________

________________________________________________________
Step 5: Diagnosis
You will now proceed to troubleshoot the problem by using the appropriate
chart. Keep in mind, you have already checked for DTC codes and have
found B0161.
What chart will you be using to diagnose the problem? _____________
________________________________________________________
The chart tells you to change your scan data display DTC function to the
real time sensor data function for ambient air.

All Rights Reserved
5-65
Student Workbook
ASE 7 - HVAC
Systems
The specifications is _______________oF to _____________oF

Is the ambient air data reading within the specified range?
YES
NO
What is the reading? ________________________________________

________________________________________________________
The next step of the diagnosis process asks you to disconnect the
ambient sensor and read the scan data for the outside temperature sensor
to see if it affects the circuit.
What does it read?
________________________________________
What does the reading tell you about the ambient sensor circuit?
_________________________________________________________
_________________________________________________________

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5-66
As you progress to the next step use a fused jumper across the ambient
connector and note the scan reading of the "outside temperature sensor."
Student Workbook
ASE 7 - HVAC
Systems
What is the reading? ________________________________________

What does the reading tell you about the circuit?
_________________________________________________________
_________________________________________________________
Step 6: Isolate the Root Cause
The final step of the chart indicates to check the connectors on both ends
of the ambient sensor harness. After checking you determine that the
problem is: (Final solution to problem)
________________________________________________________
________________________________________________________
________________________________________________________
Step 7: Repair and Verify Fix
Check with the instructor as to repairing the problem.

All Rights Reserved
5-67

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ASE 7 - Heating, Ventilation &

This module will further explore:

2002 General Motors Corporation

NATEF Area VII.

1. Diagnose temperature control problems in the heater/ventilation

2. Diagnose malfunctions in the electrical controls of heating, ventilation,

Module 5 Automatic HVAC

4. Check operation of automatic and semi-automatic heating, ventilation,

2002 General Motors Corporation

Lesson 1: Automatic HVAC Overview

The automatic HVAC system (or automatic climate control system) is

Inlet Mode Door

FULL MANUAL CONTROL

Inlet Mode Door

Figure 5-1, Full Automatic Mode versus Full Manual Mode

2002 General Motors Corporation

Refrigeration System (one of two types):

Cycling Clutch Orifice Tube (CCOT) System

Cooling System (includes the following):

Air Distribution System

Figure 5-2, Automatic HVAC Sub-Systems

2002 General Motors Corporation

Air Distribution System

Some automatic HVAC air distribution systems use different control

2002 General Motors Corporation

Figure 5-4, Automatic HVAC System using two-wire motors (Cadillac)

2002 General Motors Corporation

Inside the motor is a potentiometer that is mechanically linked to the air

Figure 5-5, Automatic HVAC System using Vacuum Solenoids (Buick)

2002 General Motors Corporation

Lesson 2: Modes of Operation

The automatic HVAC systems use a controller, Body Control Module

The SET temperature is the desired temperature that is selected by the

Exterior (Ambient) Temperature

Engine Coolant Temperature

Outlet (Duct) Temperature

Based on these inputs, the controller generates a program number. The

2002 General Motors Corporation

2002 General Motors Corporation

Figure 5-9, HVAC System Operation in Full Manual Mode

2002 General Motors Corporation

The following is an example of the manual selections and the selections

OFF (manual mode selection)

AUTO (manual mode selection)

VENT (manual mode selection)

DEFOG or FLOOR/WINDSHIELD (manual mode selection)

BI-LEVEL or MID/FLOOR (automatic and manual mode selection)

A/C or MID (automatic and manual mode selection)

HEATER or FLOOR (automatic and manual mode selection)

FRONT DEFROSTER (automatic and manual mode selection

RECIRC or MAX A/C (automatic and manual mode selection)

2002 General Motors Corporation

When OFF is selected on an automatic HVAC system, the blower motor

Figure 5-11, Automatic HVAC Air Distribution OFF Mode

2002 General Motors Corporation

In AUTO mode, all HVAC functions are controlled automatically by the

Figure 5-12, Inputs and Outputs used in AUTO Modes

2002 General Motors Corporation

A/C and rear

Heater, A/C and

The operation of the

2002 General Motors Corporation

DEFOG or FLOOR/WINDSHIELD Mode

Figure 5-14, Air Distribution System in DEFOG Mode